Corrosion protection structure

Abstract

A corrosion protection structure for a metal body having pores which communicate with the outer surface of the body is designed to protect against corrosive agents of the atmosphere and marine environments. The structure comprises an inner protective material substantially impervious to atmospheric corrosive agents disposed within the pores, the outer surface of the body being free of the material, and a solid outer protective material, different from the inner material and substantially impervious to atmospheric corrosive agents and to the inner material, covering the outer surface and the pores and intimately bonded to the outer surface. To form the corrosion protection structure, the pores of the body are impregnated with the inner protective material, preferably oil. After the impregnation, any of the inner protective material such as oil that may remain on the outer surface of the metal is selectively removed while the inner protective material in the pores is selectively retained. Thereafter, the outer protective covering material, preferably a resin, is applied over the outer surface and pores and intimately bonded to the metal surface to protect the metal from corrosion initiating from the outside. The inner protective material remains operatively disposed in the pores to protect the covering from corrosive undermining.

I claim: 
     
       1. Corrosion protection structure for a metal body having outer surface means and pore means communicating with said outer surface means, which comprises: inner protective material that is substantially impervious to atmospheric corrosive agents disposed within said pore means, said outer surface means being substantially free of said inner material, and   outer protective material which is different from said inner material and is in solid state that is substantially impervious to atmospheric corrosive agents and to said inner material forming a covering over said outer surface means and said pore means, said covering being intimately bonded to said outer surface means and bridging over said pore means.   
     
     
       2. Corrosion protection structure as defined in claim 1, wherein said inner material is not substantially combined with said outer material. 
     
     
       3. Corrosion protection structure as defined in claim 1, wherein said inner material is in liquid state. 
     
     
       4. Corrosion protection structure as defined in claim 1, wherein the bonded interface between said covering and said outer surface means at said pores is sealed by said inner material against penetration by atmospheric corrosive agents that may be entrapped in said pores. 
     
     
       5. Corrosion protection structure as defined in claim 1, wherein said inner material substantially covers the inner surface means of said metal body that is defined by said pore means. 
     
     
       6. Corrosion protection structure as defined in claim 1, wherein web means of said inner material extends across said pore means proximate the region where said pore means communicates with said outer surface means. 
     
     
       7. Corrosion protection structure as defined in claim 6, wherein said web means has concave outwardly facing surface means. 
     
     
       8. Corrosion protection structure as defined in claim 6, wherein said web means has outwardly facing surface means which directly interfaces with said covering in the region where said covering bridges over said pore means. 
     
     
       9. Corrosion protection structure as defined in claim 1, wherein said pore means is substantially filled with said inner material. 
     
     
       10. Corrosion protection structure as defined in claim 9, wherein atmospheric bubbles that may be entrapped in said pore means are encapsulated in said inner material. 
     
     
       11. Corrosion protection structure as defined in claim 1, wherein said inner material comprises oil. 
     
     
       12. Corrosion protection structure as defined in claim 1, wherein said outer material is substantially impervious to marine corrosive agents. 
     
     
       13. Corrosion protection structure as defined in claim 1, wherein said metal body comprises steel. 
     
     
       14. Corrosion protection structure as defined in claim 1, wherein said metal body comprises aluminum. 
     
     
       15. Corrosion protection structure as defined in claim 1, wherein said outer surface means has a roughened texture. 
     
     
       16. Corrosion protection structure as defined in claim 1, wherein said outer surface means has a mechanically etched texture. 
     
     
       17. Corrosion protection structure as defined in claim 1, wherein said outer surface means has a generally toothed texture. 
     
     
       18. Corrosion protection structure as defined in claim 1, wherein the edges of the openings of said pore means are generally rounded. 
     
     
       19. Corrosion protection structure as defined in claim 1, wherein said outer material comprises resin. 
     
     
       20. Corrosion protection structure as defined in claim 19, wherein said resin is reinforced with filler material. 
     
     
       21. Corrosion protection structure as defined in claim 19, wherein said inner material comprises oil.